EE 491 - Senior Design
SYS 491 - Senior Design
ME 492 - Senior Mechanical Engineering Design Project
September 15, 2015
Fall 2015 Design Project Descriptions:
Na4B, a company in the OU-INC business incubator is developing a storage battery that relies on low-cost sodium as an electrolyte. Once the final details of the battery cells are complete, they will need an enclosure to assemble up to 100 cells, in various configurations, an out the assembly through several hundred charge-discharge cycles to prove its commercial viability. The task for one or more senior design groups is to parametrically design and build this enclosure and have it ready for testing when the cells are completed.
Preliminary list of requirements and specifications:
- Individual cells are basically flat glass disks, 100-mm in diameter and 10-20 mm thick
- Battery strings are forms by connecting up to 60 cells in series
- Sodium is an efficient electrolyte at 270-350 C, but the Na4B design is such that the cells should operate at temperatures of 160-200 C.
- The battery enclosure needs to support up to 4 battery strings in either vertical or horizontal configuration, be thermally efficient and maintain a uniform temperature throughout, and incorporate a battery management system (BMS) to control charging, discharging, data for battery monitoring and testing via an interface to a connected computer.
The recently constructed OU Engineering Center building has a roof area intended for solar energy research and testing. Contractors will install a multi-panel layout of different PV panel types and mountings. The contractor will install the DC and AC wiring, as well as the infrastructure for some data monitoring. The OU Clean Energy Research Center, housed in the OU-INC business incubator, is charged with setting up the data logging and monitoring systems. This is a project for one or more senior design groups.
Preliminary list of requirements and specifications:
- design and fabricate custom racks for tracking mounts
- commission the entire system DC to AC inverter and data collection from each panel
- commission a panel temperature collection controller
- complete the design and commission two hot water systems associated with the two PV-thermal test sets
- time permitting, analysis of the collected data to make observations of the temperature vs. efficiencies of various PV types
- 01 panels c-SI_Suniva_Optimus-60-Silver.pdf
- 02 panels PVT c-Si solimpeks_Volther-Datasheet.pdf
- 03 panels CdTe First Solar FS_270.pdf
- 04 panels a-SI_SunWellSolar_Semi_DM.pdf
- 05 panels a-Si thin film solar panel technical data-4.pdf
- 06 panels CIGS_TSMC_Series_C2_Datasheet_NA_02-2014.pdf
- Easy I-O controller for temperature sensors PS_FG32_v2-5.pdf
- Easy I-O power supply FGPWR72_v1-5.pdf
- PV roof wiring diagram .pdf
- PV roof wiring diagram NOTES.pdf
- Solar Edge Communication Gateway-installation-guide.pdf
- Solar Edge control_and_communication_gateway_na.pdf
- Solar Edge Inverter-user-manual-na.pdf
- Solar Edge monitoring_performance_ratio_calculation.pdf
- Solar Edge P5-series-add-on-power-optimizer-datasheet-na.pdf
- Solar Edge single-phase-us-inverter-datasheet.pdf
- Level One L30 span table.pdf
- Quote - Clinton Aluminum - Angle for support trusses.pdf
- Racking - aluminum - fasteners.xls
Jim Leidel, September 10, 2015
PV System Tasks:
- Final layout of solar panels.
- assist contractor with selection of racking & hardware
- project management of layout [but with out seeming like you are doing any oversight :-) ]
- Installation of Optimizers [i have offered for us to do this, but it's pretty simple] contractor runs wiring
- Final design and diagram of all sensors and data acquisition - drawing
- Drawing of electrical layout
- Design layout of Hoffman panel.
- power supply
- FG32 controller
- Power Edge communication gateway (SE1000)
- terminal strip or wire management ??
- fabricate panel interior, mount and terminate wiring
- INSTALL temperature sensors and wiring back to FG32 in contractor provided conduit
- Procure a PC and located it in the EC370 lab
- work with Oakland UTC & contractor to get network drop to inverter
- commission comms to Solar Edge Communication Gateway, Inverter, and FG32 controller
- design a method to capture data: FTP or other data dump to PC database
- investigate and specify a solar radiation sensor (not yet purchased) or pyranometer
- Commission Solar Edge optimizers and inverter
- Program the EasyI/O FG32 controller with these temperature sensor inputs (i have a local contractor that will help or do this for us if needed)
Hot water system:
this is dependent upon the delivery of materials. we may have to delete this, or do the piping ourselves.
Data Collection and Study:
- finalize design drawing
- specify a 3-way control valve, temperature sensor and controller to manage the heat dump - this could be the FG32 controller (potentially)
- potentially, perform complete piping installation
- commission the BTU meter, data collection and communication back to the EC370 computer
- look a solar shading of the site. analyze the far east and far west panels
- do we need to throw out morning and late afternoon data?
- if so, how?
- read Solar Edge efficiency guidance document and design a study to use our data for the benefit of all mankind
The OU Clean Energy Research Center, housed in the OU-INC business incubator, is interested in developing a micro-CHP, or combined heat and power unit for residential applications. The unique nature is that this will be the first stage of developing a low cost air cooled unit suitable for the residential U.S. market. This is a project for one or more senior design groups.
A small displacement, single cylinder engine will be provided, converted to run on natural gas (or propane for portable use for this project). A multi-pole, permanent magnet direct current generator will be attached. An exhaust gas heat recovery unit will be fabricated and attached.
A DC power take off system will be designed and connected to the generator output. This will allow us to run and test the CHP unit under load for acoustic and thermal performance.
A task list might be as follows:
- remove fuel tank, muffler, carburetor, and pull start
- couple the DC generator to the engine
- install gaseous fuel conversion kit
- install exhaust gas heat exchanger
- fabricate engine base and sound insulated enclosure
- connect to DC power take off system (including battery / inverter setup)
- test the sound and thermal performance under load
- micro Combined Heat and Power.doc
- Honda GX series engines.doc
- OU SECS - Senior Design PROPOSAL - air cooled microCHP - Jim Leidel v.5.doc
- ME1112 PM Generator.pdf
- Heat_Exchanger - exhaust gas from Polar Power.pdf
- Tridium JACE JEC-334.pdf
- Marathon Induction Motor - dim dwg - 100294_245118_365.pdf
- Marathon Induction Motor - electrical dwg-006113157_102006_51_58877_365.pdf
Sorting small parts is a common and costly task that manufacturing facilities are faced with. In this project, we will build small devices to sort small parts
The six (6) specific parts we will sort in this project are:
- 4-mm socket head cap screws, 50-mm long
- 4-mm hex nuts
- 10-mm socket head cap screws, 25-mm long
- 10-mm hex nuts
- Both the plastic anchors and the #10 sheet metal screw components of the Triple Grip wall anchors available at Menards
Competition: On December 8, 2015 (the study day) a competition will be held for all of the parts-sorting design groups, beginning at 10 am, in 178 EC. Each team will attempt to sort a bucket of parts, consisting of 20-30 pieces of each of the six different parts, in the shortest time. Incorrect sorts will incur a 5 second penalty. The score for each run will be the time, including penalties, multiplied by the cost of the device.
We anticipate an opportunity to test a new type of fastener for military applications. This test will take no more than 2 weeks and involve no more than 3 students. When the fasteners become available, the selected students will arrange to test them at the FAJRI facilities in Dodge Hall, write a report of their findings and present the results to the fastener company and military contractors. Due to the nature of this project, this opportunity is only available to US citizens.